| Multi-layer dry paint decorative laminate having discoloration prevention barrier -> Monitor Keywords |
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Multi-layer dry paint decorative laminate having discoloration prevention barrierRelated Patent Categories: Stock Material Or Miscellaneous Articles, Layer Or Component Removable To Expose AdhesiveMulti-layer dry paint decorative laminate having discoloration prevention barrier description/claimsThe Patent Description & Claims data below is from USPTO Patent Application 20070098943, Multi-layer dry paint decorative laminate having discoloration prevention barrier. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATIONS [0001] This is a continuation-in-part of U.S. application Ser. No. 457,826, filed Jun. 9, 2003, which is a continuation-in-part of U.S. application Ser. No. 367,611, filed Feb. 14, 2003. These applications are incorporated herein in their entirety by this reference. FIELD OF THE INVENTION [0002] This invention relates generally to dry paint transfer laminates, and more particularly, to a multi-layer dry paint decorative laminate having a barrier layer that inhibits migration of discoloration-causing pigments into color-producing layers of the laminate. BACKGROUND [0003] Dry paint transfer laminates have been used in the past as surface coverings that provide an alternative to conventional painting. Water based paints and oil based paints have well known shortcomings that can be overcome by the use of decorative dry paint transfer films as a paint replacement. Environmental problems such as solvent evaporation from paint systems applied by spray painting also are avoided by use of decorative dry paint transfer films. [0004] Such decorative dry paint transfer films are typically applied to a substrate surface by an adhesive layer carried by the film. Use of heat-activated adhesives or water-activated adhesives can have certain disadvantages that are overcome by use of pressure-sensitive adhesives, by which the decorative film is adhered to the substrate surface by application of pressure only, typically at room temperature. Examples of decorative films having pressure-sensitive adhesive layers for interior or exterior applications are disclosed in U.S. Pat. No. 6,096,396 to Patton et al., U.S. Pat. No. 6,086,995 to Smith, and U.S. Pat. No. 5,229,207 to Paquette et al. [0005] Decorative films having a pressure-sensitive adhesives are often adapted to facilitate application to a surface by using various forms of repositionable adhesives known in the art. The laminate can be initially applied to a surface, removed temporarily, and then repositioned, to allow the adhesive to form a permanent bond. Decorative films having such a repositionable adhesive layer are described, for example, in the '207 patent to Paquette et al. [0006] The present invention comprises a multi-layer laminate adapted to be placed in contact with a surface which can be a painted surface. In films overlaying painted surfaces containing pigmented materials such as dyes or mono azo pigments, the colored materials may migrate or bleed into the overlaying film. This causes the finish to discolor. Pigments used in wall paints containing yellow pigments as a component, or to a lesser extent, orange or red pigments or dyes, can contain such mono azo constituents that can migrate from the wall surface through the overlaid film and into the color layer of the film, causing it to discolor. [0007] The present invention provides a multi-layer laminate adapted for contact with a painted substrate surface containing organic materials with color constituents that will bleed or migrate; and the invention addresses a situation, in particular, where the painted surface containing the migrating organic color components may not be modified to avoid the color migration problem. In response to this problem, the invention provides a laminate containing one or more barrier layers that cooperate to block or capture the migrating color materials, and in particular, those containing mono azo pigments. The barrier layer inhibits discoloration of the colored layer or layers in the laminate caused by the laminate contacting such a painted surface. SUMMARY OF THE INVENTION [0008] Briefly, the invention comprises a multi-layer laminate adapted to provide a layer of color to a painted surface. The laminate includes a pressure-sensitive adhesive for overlaying and contacting the painted surface. The laminate includes one or more barrier layers that slow or stop the migration of discoloration-causing pigments from the surface, through the adhesive layer, to the color layer of the laminate. [0009] In one embodiment, the barrier will slow or stop the color change caused by mono azo pigments in interior latex paint. By applying a barrier layer of specific polymers and/or by addition of specific additive materials to the barrier layer, the color migration may be stopped or significantly reduced. [0010] One embodiment of the invention comprises a decorative dry paint transfer laminate having a layer of dry paint, a pressure-sensitive adhesive layer on one side of the dry paint layer, and a release liner in releasable contact with the dry paint layer on a side opposite from the pressure-sensitive adhesive. The dry paint layer comprises a binder and a pigment. A barrier layer is positioned between the dry paint layer and the pressure-sensitive adhesive layer. The release liner is removable from the dry paint layer at room temperature. The pressure-sensitive adhesive is adapted for adhering the laminate to a substrate surface at room temperature. The substrate surface can be a painted wall surface containing organic materials with color that can bleed or migrate. The pressure-sensitive adhesive layer adheres the laminate to the substrate surface under application of pressure. The release liner is then peeled away from the dry paint layer. The barrier layer comprises a thin, flexible film made from a material that stops or appreciably reduces migration of discoloration-causing constituents migrating from the painted surface through the adhesive layer to the color layer. In one embodiment, the barrier layer can comprise a polymeric material having a cross-linking density sufficient to inhibit transmission of discoloration-causing pigments and/or a dispersed additive that may capture or retard the migration of discoloration-causing pigments. The barrier layer is particularly useful in retarding or inhibiting the transmission of azo-type pigments and is present at a low coat weight or thickness which does not significantly increase the overall thickness of a decorative film. In one embodiment, the barrier thickness is no more than about 10% of the total thickness of the decorative film (excluding the outer releasable carrier film). [0011] These and other aspects of the invention will be more fully understood by referring to the following detailed description and the accompanying drawings. BRIEF DESCRIPTION OF THE DRAWINGS [0012] FIG. 1 is a schematic cross-sectional view illustrating one embodiment of a multi-layer dry paint transfer laminate according to principles of this invention. [0013] FIG. 2 is a schematic illustration of the dry paint transfer laminate self-wound into a roll form. [0014] FIG. 3 is a schematic cross-sectional view showing an alternative embodiment of a dry paint layer contained in the laminate. [0015] FIG. 4 is a schematic cross-sectional view showing another alternative embodiment of the dry paint layer. [0016] FIG. 5 is a schematic cross-sectional view illustrating an alternative embodiment of the dry paint layer of FIG. 4. [0017] FIG. 6 is a schematic cross-sectional view illustrating an embodiment containing a support layer. [0018] FIG. 7 is a schematic cross-sectional view illustrating an embodiment containing a barrier layer. [0019] FIG. 8 is a schematic illustration of a process for co-extruding a support layer and an adhesive layer used in one embodiment of the invention. Continue reading about Multi-layer dry paint decorative laminate having discoloration prevention barrier... Full patent description for Multi-layer dry paint decorative laminate having discoloration prevention barrier Brief Patent Description - Full Patent Description - Patent Application Claims Click on the above for other options relating to this Multi-layer dry paint decorative laminate having discoloration prevention barrier patent application. ###  How KEYWORD MONITOR works... a FREE service from FreshPatents1. Sign up (takes 30 seconds). 2. Fill in the keywords to be monitored. 3. Each week you receive an email with patent applications related to your keywords. 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